Systems and methods for additive manufacturing systems implementing adaptive optics in accordance with various embodiments of the invention are illustrated. One embodiment includes an additive manufacturing system including a laser source configured to form an output beam, a scanning mirror disposed in an optical path of the output beam, wherein the scanning mirror is configured to reflect and scan the output beam at a range of scan angles, a deformable mirror disposed in the optical path of the output beam, wherein the deformable mirror has a plurality of configurations for reflecting and altering a wavefront of the output beam, wherein the configuration of the deformable mirror is based on the scan angle of the scanning mirror, and a print bed configured to hold a print material, wherein the output beam is configured to fuse the print material to form a build object.

Systems and methods for additive manufacturing systems implementing adaptive optics in accordance with various embodiments of the invention are illustrated. One embodiment includes an additive manufacturing system including a laser source configured to form an output beam, a scanning mirror disposed in an optical path of the output beam, wherein the scanning mirror is configured to reflect and scan the output beam at a range of scan angles, a deformable mirror disposed in the optical path of the output beam, wherein the deformable mirror has a plurality of configurations for reflecting and altering a wavefront of the output beam, wherein the configuration of the deformable mirror is based on the scan angle of the scanning mirror, and a print bed configured to hold a print material, wherein the output beam is configured to fuse the print material to form a build object.

Embodiments of bladed rotors and methods for manufacturing bladed rotors are provided herein. The method for manufacturing bladed rotors includes providing a workpiece including a first rotor blade segment. The first rotor blade segment includes a first platform portion on a radially outward end portion of the first rotor blade segment. Further, the method includes forming a second rotor blade segment, by additive manufacturing, removing a side portion of the first platform portion, and removing a side portion of the second rotor blade segment, whereby a second platform portion remains on a radially outward end portion of the second rotor blade segment.

Embodiments of bladed rotors and methods for manufacturing bladed rotors are provided herein. The method for manufacturing bladed rotors includes providing a workpiece including a first rotor blade segment. The first rotor blade segment includes a first platform portion on a radially outward end portion of the first rotor blade segment. Further, the method includes forming a second rotor blade segment, by additive manufacturing, removing a side portion of the first platform portion, and removing a side portion of the second rotor blade segment, whereby a second platform portion remains on a radially outward end portion of the second rotor blade segment.

An irradiation device for additively manufacturing three-dimensional objects may include a beam generation device that includes a plurality of laser diode arrays. Respective ones of the plurality of laser diode arrays may include a plurality of diode emitters respectively configured to emit an energy beam. The plurality of laser diode arrays may be longitudinally offset relative to one another, and the plurality of laser diode arrays may be laterally offset relative to one another.

An irradiation device for additively manufacturing three-dimensional objects may include a beam generation device that includes a plurality of laser diode arrays. Respective ones of the plurality of laser diode arrays may include a plurality of diode emitters respectively configured to emit an energy beam. The plurality of laser diode arrays may be longitudinally offset relative to one another, and the plurality of laser diode arrays may be laterally offset relative to one another.

An annular hollow offset-focus laser cladding device, including a housing, a conical reflector arranged in the housing, an annular off-axis parabolic focusing mirror opposite to and arranged coaxially with the conical reflector, a nozzle installed below the conical reflector and a powder-spraying tube connected to a lower end of the nozzle. A top of the housing is provided with a light entrance; the conical reflector faces the light entrance; The powder-spraying tube is coaxial with the annular hollow offset-focusing light reflected by the annular off-axis parabolic focusing mirror; a collimating protective gas jacket is arranged on a periphery of the powder-spraying tube, and the collimating protective gas jacket is located between the annular hollow offset-focused light and the powder-spraying tube; the annular off-axis parabolic focusing mirror is configured to create a horizontally offset of parent parabola focus.

An annular hollow offset-focus laser cladding device, including a housing, a conical reflector arranged in the housing, an annular off-axis parabolic focusing mirror opposite to and arranged coaxially with the conical reflector, a nozzle installed below the conical reflector and a powder-spraying tube connected to a lower end of the nozzle. A top of the housing is provided with a light entrance; the conical reflector faces the light entrance; The powder-spraying tube is coaxial with the annular hollow offset-focusing light reflected by the annular off-axis parabolic focusing mirror; a collimating protective gas jacket is arranged on a periphery of the powder-spraying tube, and the collimating protective gas jacket is located between the annular hollow offset-focused light and the powder-spraying tube; the annular off-axis parabolic focusing mirror is configured to create a horizontally offset of parent parabola focus.

An additive manufacturing system includes one or more light sources and one or more light valves that can be written with two-dimensional gray scale patterns that the light valves impose on beams from the one or more light sources to obtain one or more patterned beams. The one or more patterned beams are steered to each area of a plurality of areas on a layer of powder. The two-dimensional gray scale patterns are selected to achieve desired material properties at each pixel position of the patterned beam incident on the layer of powder. The light valves may modulate one or more of amplitude, phase, or coherence. The material properties may include one or more of Young's modulus, porosity, grain size, and crystalline microstructure.

The illumination optical system includes a beam shaper which converts an intensity distribution of a laser beam in each of a short axis direction and a long axis direction, which is a Gaussian distribution, into an intensity distribution of a parallel beam on a modulation surface of the optical modulator in each of the short axis direction and the long axis direction, which is a top hat distribution. The modulation surface and an irradiated surface are optically conjugated with respect to the long axis direction by a third lens and a fourth lens. Further, the modulation surface and a front focus position of the fourth lens are optically conjugated with respect to the short axis direction by a first lens, a second lens, and the third lens. The fourth lens condenses a beam having a top hat distribution at the front focus position onto the irradiated surface.